KYMCO Downtown 125i 2009 Service Manual

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DOWNTOWN 125i

By KWANG YANG Motor Co., Ltd.

1st Edition, April 2009

unauthorized use without the written

permission of KWANG YANG Motor Co., Ltd.

is expressly prohibited.

T100-LFA7-A2

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Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for KYMCO Downtown 125i 2009

Page 1 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i By KWANG YANG Motor Co., Ltd. 1st Edition, April 2009 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. T100-LFA7-A2 Cortesia de/ Courtesy of: www.batmotos.com...
Page 2: Table Of Contents
DOWNTOWN 125i PREFACE TABLE OF CONTENTS This Service Manual describes the GENERAL INFORMATION technical features servicing EXHAUST MUFFLER/FRAME procedures KYMCO Downtown 125i. COVERS INSPECTION/ADJUSTMENT Section 1 contains the precautions for all operations stated in this manual. LUBRICATION SYSTEM Read them carefully before operation is started.
Page 3: General Information
Cortesia de/ Courtesy of: www.batmotos.com 1. GENERAL INFORMATION DOWNTOWN 125i ENGINE SERIAL NUMBER LUBRICATION POINTS..........1- 1 1-14 SPECIFICATIONS ........SERVICE PRECAUTIONS ..... TORQUE VALUES ........SPECIAL TOOLS........1-12 ENGINE SERIAL NUMBER Location of Engine Serial Number - 1 - Cortesia de/ Courtesy of: www.batmotos.com...
Page 4 Cortesia de/ Courtesy of: www.batmotos.com 1. GENERAL INFORMATION DOWNTOWN 125i SPECIFICATIONS Air cleaner type & No Paper element, wet Fuel capacity 12.5 L Name DOWNTOWN125i Model No. SK25AA Butterfly type Throttle type Overall length 2200mm Overall width 800 mm Overall height 1410 mm Type Wheel base...
Page 5 Cortesia de/ Courtesy of: www.batmotos.com 1. GENERAL INFORMATION DOWNTOWN 125i SERVICE PRECAUTIONS Make sure to install new gasket, O-rings, circlips, cotter pins, etc. When reassembling. When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to specified torque diagonally.
Page 6 Cortesia de/ Courtesy of: www.batmotos.com 1. GENERAL INFORMATION DOWNTOWN 125i Apply or add designated greases and lubricants to the specified lubrication points. After reassembly, check all parts for proper tightening and operation. When two person work together, pay attention to the mutual working safety. Disconnect the battery negative (-) terminal before operation.
Page 7 Cortesia de/ Courtesy of: www.batmotos.com 1. GENERAL INFORMATION DOWNTOWN 125i If the fuse is burned out, find the cause Confirm and repair it. Replace it with a new one Capacity according to the specified capacity. After operation, terminal caps shall be installed securely.
Page 8 Cortesia de/ Courtesy of: www.batmotos.com 1. GENERAL INFORMATION DOWNTOWN 125i The connector shall be inserted completely. click If the double connector has a lock, lock it at the correct position. Check if there is any loose wire. Before connecting a terminal, check for damaged terminal cover or loose negative terminal.
Page 9 Cortesia de/ Courtesy of: www.batmotos.com 1. GENERAL INFORMATION DOWNTOWN 125i After clamping, check each wire to make sure it is secure. Do not squeeze wires against the weld or its clamp After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts.
Page 10 Cortesia de/ Courtesy of: www.batmotos.com 1. GENERAL INFORMATION DOWNTOWN 125i Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tight! Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner.
Page 11 Cortesia de/ Courtesy of: www.batmotos.com 1. GENERAL INFORMATION DOWNTOWN 125i After routing, check that the wire harnesses are not twisted or kinked. Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions.
Page 12 Cortesia de/ Courtesy of: www.batmotos.com 1. GENERAL INFORMATION DOWNTOWN 125i Symbols : The following symbols represent the servicing methods and cautions included in this service manual. :Apply engine oil to the specified points. (Use designated engine oil for lubrication). Engine Oil :Apply grease for lubrication.
Page 13 Cortesia de/ Courtesy of: www.batmotos.com 1. GENERAL INFORMATION DOWNTOWN 125i TORQUE VALUES STANDAR TORQUE VALUES Item Torque (kg - f m) Item (kg - f m) 5mm bolt, nut 0.45~0.6 5mm screw 0.45~0.6 6mm bolt, nut 0.8~1.2 6mm screw, SH bolt 0.7~1.1 8mm bolt, nut 1.8~2.5...
Page 14 Cortesia de/ Courtesy of: www.batmotos.com 1. GENERAL INFORMATION DOWNTOWN 125i SPECIAL TOOLS Illustration (Note: the special tools may differ Tool Name Tool No. slightly from those shown in the figure of this manual.) Flywheel puller (Refer to the “STARTER A120E00003 CLUTCH”...
Page 15 Cortesia de/ Courtesy of: www.batmotos.com 1. GENERAL INFORMATION DOWNTOWN 125i SPECIAL TOOLS Illustration (Note: the special tools may differ Tool Name Tool No. slightly from those shown in the figure of this manual.) Bearing puller A120E00037 Valve spring compressor (Refer to the “CYLINDER A120E00040 HEAD”...
Page 16 DOWNTOWN 125i LUBRICATION POINTS ENGINE Lubrication Points Lubricant Valve guide/valve stem movable part Genuine KYMCO Engine Oil (SAE15W-40) Cam lobes API , SJ Engine Oil Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves...
Page 17: Exhaust Muffler/Frame Covers
Cortesia de/ Courtesy of: www.batmotos.com . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUST MUFFLER/FRAME COVERS __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 2- 1 TROUBLESHOOTING----------------------------------------------------- 2- 1 FASTENER REMOVAL AND REINSTALLATION------------------ 2- 2 FRAME COVERS REMOVAL/INSTALLATION --------------------- 2- 3 EXHAUST MUFFLER ----------------------------------------------------- 2-14 Cortesia de/ Courtesy of: www.batmotos.com...
Page 18: Exhaust Muffler/Frame Covers
Cortesia de/ Courtesy of: www.batmotos.com . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 125i SERVICE INFORMATION GENERAL INSTRUCTIONS • When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged. • Make sure to route cables and harnesses according to the Cable & Harness Routing. TORQUE VALUES Exhaust muffler pipe nuts 1.8~2.2 kgf-m...
Page 19: Fastener Removal And Reinstallation
Cortesia de/ Courtesy of: www.batmotos.com . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 125i FASTENER REMOVAL AND REINSTALLATION REMOVAL Depress the head of fastener center piece . Pull out the fastener. INSTALLATION Let the center piece stick out toward the head so that the pawls close.
Page 20: Frame Covers Removal/Installation
Cortesia de/ Courtesy of: www.batmotos.com . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 125i FRAME COVERS REMOVAL/ INSTALLATION SEAT Unlock the seat with the ignition key. Open the seat. Remove the two nuts and the seat. Installation is in the reverse order of removal. LUGGAGE BOX Unlock the seat with the ignition key.
Page 21 Cortesia de/ Courtesy of: www.batmotos.com . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 125i Center Cover CENTER COVER Remove the luggage box. Remove the center cover. ＊ During removal, do not pull the joint claws forcedly to avoid damage. Installation is in the reverse order of removal. Remove four bolts and , then remove the rear carrier.
Page 22 Cortesia de/ Courtesy of: www.batmotos.com . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 125i Installation is in the reverse order of removal. UPPER/LOWER HANDLEBAR COVER Remove the four screws. then remove upper handlebar cover. Remove the four screws, then remove the bottom handlebar cover. Disconnect the throttle cable refer to the “THROTTLE BODY /TPS”...
Page 23 Cortesia de/ Courtesy of: www.batmotos.com . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 125i WINDSHIELD/WINDSHIELD GARNISH Remove five bolts and windshield garnish. Cortesia de/ Courtesy of: www.batmotos.com...
Page 24 Cortesia de/ Courtesy of: www.batmotos.com . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 125i FRONT CENTER COVER Remove the windshield Remove four screws, then remove the front center cover. Remove the front cover. Installation is in the reverse order of removal. FRONT COVER Remove the small front cover(black) screw Remove the small front cover(black) Remove two nuts.
Page 25 Cortesia de/ Courtesy of: www.batmotos.com . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 125i Disconnect the headlight/position light connect and right/left turn signal light connectors. Installation is in the reverse order of removal. FRONT FENDER Remove four screws. screws and front fender. Installation is in the reverse order of removal. RIGHT/LEFT FOOT SKIRT Remove the six screws attaching to the right or left skirt.
Page 26 Cortesia de/ Courtesy of: www.batmotos.com . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 125i FRONT LOWER COVER Remove the front cover Remove the foot skirt Remove seven screws and front lower cover. Installation is in the reverse order of removal. REAR FENDER Remove the body cover and then the rear fender .
Page 27 Cortesia de/ Courtesy of: www.batmotos.com . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 125i Taillight Connector Disconnect the taillight connector. Installation is in the reverse order of removal. TIRE FENDER Remove the body cover . Remove four bolts attaching to the tire fender Installation is in the reverse order of removal.
Page 28 Cortesia de/ Courtesy of: www.batmotos.com . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 125i Remove eight bolts, then remove the floorboard. UNDER COVER Remove four bolts Remove the under cover. 2-11 Cortesia de/ Courtesy of: www.batmotos.com...
Page 29 Cortesia de/ Courtesy of: www.batmotos.com . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 125i Remove the fuel tank cap cover. Installation is in the reverse order of removal. Speedometer Wires METER PANEL Disconnect the speedometer wires. Disconnect the DC power connectors. DC power Connectors Remove one screws Remove the ignition key garnish Remove three screws from the inner cover,...
Page 30 Cortesia de/ Courtesy of: www.batmotos.com . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 125i INNER COVER Remove the front cover . Remove the front lower cover . Remove the floorboard Remove four bolts and front glove box one screw. Remove two fastener bolts then remove the fuel tank fill cap.
Page 31: Exhaust Muffler
Cortesia de/ Courtesy of: www.batmotos.com . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 125i EXHAUST MUFFLER REMOVAL Disconnect the O2 heater/O2 sensor connector . Remove the two exhaust pipe joint nuts Remove three muffler mount bolts and muffler and gasket. 2-14 Cortesia de/ Courtesy of: www.batmotos.com...
Page 32 Cortesia de/ Courtesy of: www.batmotos.com . EXHAUST MUFFLER/FRAME COVERS DOWNTOWN 125i INSTALLATION Replace the gasket with a new one. Install the exhaust muffler and three mounting bolt. Install and tighten the two exhaust pipe joint nuts to the specified torque Torque: 20 N•m (2 kgf•m,) Tighten the three mounting bolts Torque: 35 N•m (3.5 kgf•m,)
Page 33: Inspection/Adjustment
Cortesia de/ Courtesy of: www.batmotos.com . INSPECTION/ADJUSTMENT DOWNTOWN 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSPECTION/ADJUSTMENT __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 3- 1 MAINTENANCE SCHEDULE-------------------------------------------- 3- 2 FUEL LINE------------------------------------------------------------------- 3- 4 THROTTLE OPERATION------------------------------------------------- 3- 4 ENGINE OIL ----------------------------------------------------------------- 3- 5 TRANSMISSION OIL ------------------------------------------------------ 3-11 AIR CLEANER -------------------------------------------------------------- 3-12 SPARK PLUG---------------------------------------------------------------- 3-13 VALVE CLEARANCE ----------------------------------------------------- 3-14...
Page 34: Inspection/Adjustment
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . INSPECTION/ADJUSTMENT SERVICE INFORMATION GENERAL ！ WARNING •Before running the engine, make sure that the working area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may cause death to people. •Gasoline is extremely flammable and is explosive under some conditions.
Page 35: Maintenance Schedule
KYMCO by properly trained and equipped technicians. Your KYMCO dealer meets all of these requirements. ＊Should be serviced by your KYMCO dealer, unless the owner has the proper tools and service data and is mechanically qualified. ＊＊In the interest of safety, we recommend these items be serviced only by your KYMCO dealer.
Page 36 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . INSPECTION/ADJUSTMENT MAINTENANCE SCHEDULE FREQUENCY WHICHEVER ODOMETER READING COMES FIRST X 1000 km 10 15 20 25 30 REFER 0.6 3 9 12 15 18 X 1000 mi PAGE ITEM MONTH AIR CLEANER SPARK PLUGS THROTTLE OPERATION VALVE CLEARANCE...
Page 37: Fuel Line
Cortesia de/ Courtesy of: www.batmotos.com . INSPECTION/ADJUSTMENT DOWNTOWN 125i FUEL LINE Check the fuel lines and replace any parts which show signs of deterioration, damage or leakage. THROTTLE OPERATION Check the throttle grip for smooth movement. Measure the throttle grip free play. Free Play: 2～6 mm Major adjustment of the throttle grip free play is made with the adjusting nut at the throttle body...
Page 38: Engine Oil
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . INSPECTION/ADJUSTMENT Minor adjustment is made with the adjusting nut at the throttle grip side. Slide the rubber cover (1) out and adjust by loosening the lock nut (3) and turning the adjusting nut (2). (Chart) ENGINE OIL VISCOSITIES 20W-40, 20W-50...
Page 39 Cortesia de/ Courtesy of: www.batmotos.com . INSPECTION/ADJUSTMENT DOWNTOWN 125i Engine oil replacement Engine oil quality is the chief factor affecting engine service life. Change the engine oil as specified in the maintenance schedule. When running in very dusty conditions, oil changes should be performed more frequently than specified in the maintenance schedule.
Page 40 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . INSPECTION/ADJUSTMENT 1. Remove the oil filler cap/dipstick(1) from the right crankcase cover. 2. Place a container under the left crankcase. 3. Remove the oil drain plug (2) to drain the oil. 4. Reinstall the drain plug and tighten the drain plug to specification.
Page 41 Cortesia de/ Courtesy of: www.batmotos.com . INSPECTION/ADJUSTMENT DOWNTOWN 125i Oil strainer screen clean Change the engine oil with the engine at normal operating temperature and the scooter on its center stand to assure complete and rapid draining. ＊ Let the engine and exhaust system cool before working in those areas.
Page 42 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . INSPECTION/ADJUSTMENT Oil filter replacement Change the engine oil with the engine at normal operating temperature and the scooter on its center stand to assure complete and rapid draining. ＊ Let the engine and exhaust system cool before working in those areas.
Page 43 Cortesia de/ Courtesy of: www.batmotos.com . INSPECTION/ADJUSTMENT DOWNTOWN 125i 5. Install the new oil filter. ＊ Make sure the rubber seal on the oil filter facing the left crankcase. Rubber Seal 6. Install the spring, O-ring and cap. Torque: 12 N-m (1.2 kgf-m) 7.
Page 44: Transmission Oil
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . INSPECTION/ADJUSTMENT TRANSMISSION OIL Oil change 1. Place the scooter in its center stand. 2. Place a drain pan under the drain bolt (1). 3. Remove the transmission oil drain bolt. 4. Remove the transmission oil filler bolt (2), slowly turn the rear wheel and drain the oil.
Page 45: Air Cleaner
Use the KYMCO genuine air cleaner element or an equivalent air cleaner element specified for your model. Using the wrong KYMCO air cleaner element or a non-KYMCO air cleaner element which is not of equivalent quality may cause premature engine wear or performance problems.
Page 46: Spark Plug
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . INSPECTION/ADJUSTMENT SPARK PLUG Remove the spark plug cap and spark plug Check the spark plug for wear and fouling deposits. Clean any fouling deposits with a spark plug cleaner or a wire brush. Specified Spark Plug: NGK CR7E Cracks...
Page 47: Valve Clearance
Cortesia de/ Courtesy of: www.batmotos.com . INSPECTION/ADJUSTMENT DOWNTOWN 125i VALVE CLEARANCE ＊ • Inspect and adjust valve clearance while the engine is cold (below 35℃). Remove the four bolts , then remove cylinder head cover. Timing hole cap Remove the timing hole cap and O-ring Remove the crankshaft hole cap and O-ring .
Page 48: Idle Speed
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . INSPECTION/ADJUSTMENT Adjust by loosening the valve adjusting screw lock-nut and turning the adjusting screw until there is a slight drag on the thickness gauge . Valve Clearance: IN: 0.1 mm EX:0.1 mm Apply oil to the valve adjusting screw lock- nut threads and seating surface.
Page 49: Cylinder Compression
Cortesia de/ Courtesy of: www.batmotos.com . INSPECTION/ADJUSTMENT DOWNTOWN 125i CYLINDER COMPRESSION Warm up the engine before compression test. Remove the center cover and spark plug cap. Remove the spark plug . Insert a compression gauge. Open the throttle valve fully and push the starter button to test the compression.
Page 50: Clutch Shoe Wear
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . INSPECTION/ADJUSTMENT CLUTCH SHOE WEAR Start the engine and check the clutch operation by increasing the engine speed gradually. If the scooter tends to creep, or the engine stalls, check the clutch shoes for wear and replace if necessary (refer to the “DRIVE PULLEY, DRIVE BELT AND DRIVEN PULLEY”...
Page 51: Coolant
Always add coolant to the reserve tank. Do not attempt to add coolant by removing the radiator cap. If the reserve tank is empty, or if coolant loss is excessive, check for leaks and see your KYMCO dealer for repair. 3-18 Cortesia de/ Courtesy of: www.batmotos.com...
Page 52: Brake Fluid
Front brake /Rear brake Check the cutout in each pad. If either pad is worn to the cutout, replace both pads as a set. See your KYMCO dealer Rear brake for this service. 3-19 Cortesia de/ Courtesy of: www.batmotos.com...
Page 53: Nuts/Bolts/Fasteners
Cortesia de/ Courtesy of: www.batmotos.com . INSPECTION/ADJUSTMENT DOWNTOWN 125i NUTS/BOLTS/FASTENERS Check all important chassis nuts and bolts for looseness. Tighten them to their specified torque values if any looseness is found. WHEELS/TIRES Tire pressure Insufficient air pressure in the tires not only hastens tire wear but also seriously affects the stability of the scooter.
Page 54: Suspension
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . INSPECTION/ADJUSTMENT SUSPENSION Check the action of the front/rear shock absorbers by compressing them several times. Check the entire shock absorber assembly for oil leaks, looseness or damage. Jack the rear wheel off the ground and move the rear wheel sideways with force to see if the engine hanger bushings are worn.
Page 55: Side Stand
2. Put the side stand up and start the engine. 3. Lower the side stand. The engine should stop as you put the side stand down. If the side stand system does not operate as described, see your KYMCO dealer for service. Side stand down 3-22...
Page 56: Lubrication System
Cortesia de/ Courtesy of: www.batmotos.com . LUBRICATION SYSTEM DOWNTOWN 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ LUBRICATION SYSTEM DIAGRAM ---------------------------------- 4-1 SERVICE INFORMATION------------------------------------------------ 4-2 TROUBLESHOOTING----------------------------------------------------- 4-2 OIL PUMP ------------------------------------------------------------------- 4-3 Cortesia de/ Courtesy of: www.batmotos.com...
Page 57: Lubrication System
Cortesia de/ Courtesy of: www.batmotos.com . LUBRICATION SYSTEM DOWNTOWN 125i LUBRICATION SYSTEM DIAGRAM Rocker Arm Shaft Crankshaft Oil Strainer Screen Oil Pump Oil Filter Screen Cortesia de/ Courtesy of: www.batmotos.com...
Page 58: Service Information
Cortesia de/ Courtesy of: www.batmotos.com . LUBRICATION SYSTEM DOWNTOWN 125i SERVICE INFORMATION GENERAL INSTRUCTIONS • The maintenance of lubrication system can be performed with the engine installed in the frame. • Drain the coolant before starting any operations. • Be careful when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.
Page 59: Oil Pump
Cortesia de/ Courtesy of: www.batmotos.com . LUBRICATION SYSTEM DOWNTOWN 125i OIL PUMP Bolts REMOVAL Remove the flywheel and driven gear (refer to the “STARTER CLUTCH” section in the chapter 10). Remove the bolt and then oil separator cover. ＊ When removing and installing the oil pump, be careful not to allow dust or dirt to enter the engine.
Page 60 Cortesia de/ Courtesy of: www.batmotos.com . LUBRICATION SYSTEM DOWNTOWN 125i Arrow Mark INSTALLATION Install the oil pump and oil separator and tighten the two bolts. The arrow mark must be keep upward. ＊ Make sure the pump shaft rotates freely and arrow on the oil pump is upside.
Page 61 Cortesia de/ Courtesy of: www.batmotos.com . LUBRICATION SYSTEM DOWNTOWN 125i DISASSEMBLY Remove the screw and disassemble the oil pump as shown. Pump Cover Outer Rotor Inner Rotor Pump Body Screw Dowel Pin Pump Shaft ASSEMBLY Pump Body Dowel Pin Install the outer rotor, inner rotor and pump shaft into the pump body.
Page 62: Engine Removal/Installation
Cortesia de/ Courtesy of: www.batmotos.com . ENGINE REMOVAL/INSTALLATION DOWNTOWN 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 5-1 ENGINE REMOVAL/INSTALLATION--------------------------------- 5-2 ENGINE HANGER --------------------------------------------------------- 5-8 Cortesia de/ Courtesy of: www.batmotos.com...
Page 63 Cortesia de/ Courtesy of: www.batmotos.com 5. ENGINE REMOVAL/INSTALLATION DOWNTOWN 125i SERVICE INFORMATION GENERAL INSTRUCTIONS • A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the scooter body, cables and wires during engine removal. •...
Page 64 Cortesia de/ Courtesy of: www.batmotos.com . ENGINE REMOVAL/INSTALLATION DOWNTOWN 125i ENGINE REMOVAL/INSTALLATION REMOVAL ＊ Remove the air cleaner Disconnect the ECU connector (A) Disconnect the O2 heater/O2 sensor connector Disconnect the throttle cable(B) ＊ Remove a bolt from fuel hose guide (C). Disconnect the fuel hose (D) from fuel injector.
Page 65 Cortesia de/ Courtesy of: www.batmotos.com 5. ENGINE REMOVAL/INSTALLATION DOWNTOWN 125i Loosen the rear axle nut. Support the scooter securely on its main stand. Remove three bolts (1) attaching to rear brake hose clamps. Remove the two bolts (2), then remove the rear brake caliper.
Page 66 Cortesia de/ Courtesy of: www.batmotos.com . ENGINE REMOVAL/INSTALLATION DOWNTOWN 125i Remove the bolts and engine ground cable. Remove the two nuts (7), then remove the intake manifold from cylinder head. Remove the bolt (8), then remove the thermostat from cylinder head. Remove the spark plug cap .
Page 67 Cortesia de/ Courtesy of: www.batmotos.com 5. ENGINE REMOVAL/INSTALLATION DOWNTOWN 125i Disconnect the lower radiator hose from lower radiator pipe. Remove the right and left rear shock absorber lower mount bolts . Cortesia de/ Courtesy of: www.batmotos.com...
Page 68 Cortesia de/ Courtesy of: www.batmotos.com . ENGINE REMOVAL/INSTALLATION DOWNTOWN 125i Remove the engine mount nut Pull out the engine mount bolt. Remove the engine from the frame. ＊ At removing the engine, be careful not to catch your hand or finger between the engine hanger and crankcase.
Page 69 Cortesia de/ Courtesy of: www.batmotos.com 5. ENGINE REMOVAL/INSTALLATION DOWNTOWN 125i INSTALLATION Installation is in the reverse order of removal. Tighten the engine mounting bolt/nut to the specified torque. Torque: 5 kgf-m (50 N-m) Tighten the right and left rear shock absorber lower mount bolts to the specified torque.
Page 70 Cortesia de/ Courtesy of: www.batmotos.com . ENGINE REMOVAL/INSTALLATION DOWNTOWN 125i ENGINE HANGER REMOVAL Remove the engine mount nut . Pull the engine mount bolt out. ＊ Be careful to put the engine down. Remove the left engine hanger mount bolt . Remove the right engine hanger mount bolt and collar .
Page 71: Cylinder Head/Valves
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . CYLINDER HEAD/VALVES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD/VALVES __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 6- 1 SERVICE INFORMATION------------------------------------------------ 6- 2 TROUBLESHOOTING----------------------------------------------------- 6- 3 CYLINDER HEAD COVER----------------------------------------------- 6- 4 CAMSHAFT HOLDER----------------------------------------------------- 6- 5 CAMSHAFT ----------------------------------------------------------------- 6- 8 CYLINDER HEAD---------------------------------------------------------- 6- 13 Cortesia de/ Courtesy of: www.batmotos.com...
Page 72: Cylinder Head/Valves
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . CYLINDER HEAD/VALVES SCHEMATIC DRAWING Cortesia de/ Courtesy of: www.batmotos.com...
Page 73: Service Information
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . CYLINDER HEAD/VALVES SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water jacket must be drained first. • When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication.
Page 74: Troubleshooting
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . CYLINDER HEAD/VALVES SPECIAL TOOLS Valve spring compressor A120E00040 TROUBLESHOOTING • The poor cylinder head operation can be diagnosed by a compression test or by tracing engine Poor performance at idle speed White smoke from exhaust muffler •...
Page 75: Cylinder Head Cover
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . CYLINDER HEAD/VALVES CYLINDER HEAD COVER REMOVAL Remove four bolts then remove the cylinder head cover. INSTALLATION Install a new cylinder head cover O-ring and install the cylinder head cover. ＊ Be sure to install the O-ring into the groove properly.
Page 76: Camshaft Holder
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . CYLINDER HEAD/VALVES CAMSHAFT HOLDER REMOVAL Turn the A.C. generator flywheel so that the T mark on the flywheel aligns with the index mark on the crankcase. Hold the round hole on the camshaft gear facing up and location is the top dead center on the compression stroke.
Page 77 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . CYLINDER HEAD/VALVES DISASSEMBLY Take out the valve rocker arm shafts Remove the valve rocker arms. Rocker Arm Shafts INSPECTION Camshaft Holder Inspect the camshaft holder, valve rocker arms and rocker arm shafts for wear or damage.
Page 78 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . CYLINDER HEAD/VALVES ASSEMBLY Rocker Arm Shafts Apply engine oil to the rocker arms and rocker arm shafts. Install the rocker arms and shafts into the camshaft holder. ＊ • Install the exhaust valve rocker arm shaft on the “EX”...
Page 79: Camshaft
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . CYLINDER HEAD/VALVES Tensioner Sealing Bolt CAMSHAFT REMOVAL Turn the A.C. generator flywheel so that the “T” mark on the flywheel aligns with the index mark on the crankcase. Hold the round hole on the camshaft gear facing up and the location is the top dead center on the compression stroke.
Page 80 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . CYLINDER HEAD/VALVES INSPECTION Camshaft Inspect camshaft lobes for pitting/scratches/blue discoloration. If any defects are found, replace the camshaft with a new one, then inspect lubrication Camshaft Bearings system. Check each camshaft bearing for play or damage.
Page 81 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . CYLINDER HEAD/VALVES Punch Marks INSTALLATION Turn the A.C. generator flywheel so that the “T” mark on the flywheel aligns with the index mark on the crankcase. Keep the round hole on the camshaft gear facing up and align the punch marks on the camshaft gear with the cylinder head surface (Position the intake and exhaust cam lobes...
Page 82 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . CYLINDER HEAD/VALVES Valve Spring Compressor DISASSEMBLY Remove the valve spring cotters, retainers, springs, spring seats, oil seals and valves using a valve spring compressor. ＊ • Be sure to compress the valve springs with a valve spring compressor.
Page 83 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . CYLINDER HEAD/VALVES INSPECTION Remove carbon deposits from the exhaust Combustion Chamber port and combustion chamber. ＊ Be careful not to damage the cylinder head mating surface. Exhaust Port Valve /Valve guide Inspect each valve for bending, burning, scratches or abnormal stem wear.
Page 84: Cylinder Head
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . CYLINDER HEAD/VALVES Cylinder head Check the spark plug hole and valve areas for cracks. Check the cylinder head for warpage with a straight edge and feeler gauge. Service Limit: 0.05 mm Valve Spring Compressor ASSEMBLY Install the valve spring seats and oil seal.
Page 85: Cylinder/Piston
Cortesia de/ Courtesy of: www.batmotos.com . CYLINDER/PISTON DOWNTOWN 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER/PISTON __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 7-1 SERVICE INFORMATION------------------------------------------------ 7-2 TROUBLESHOOTING----------------------------------------------------- 7-3 CYLINDER AND PISTON ------------------------------------------------ 7-4 Cortesia de/ Courtesy of: www.batmotos.com...
Page 86: Cylinder/Piston
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . CYLINDER/PISTON SCHEMATIC DRAWING Cortesia de/ Courtesy of: www.batmotos.com...
Page 87: Service Information
Cortesia de/ Courtesy of: www.batmotos.com . CYLINDER/PISTON DOWNTOWN 125i SERVICE INFORMATION GENERAL INSTRUCTIONS • When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed. • After disassembly, clean the removed parts and dry them with compressed air before inspection. Unit: mm SPECIFICATIONS Standard...
Page 88: Troubleshooting
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . CYLINDER/PISTON TROUBLESHOOTING • When hard starting or poor performance at low speed occurs, check the crankcase breather for white smoke. If white smoke is found, it means that the piston rings are worn, stuck or broken. Compression too low or uneven compression Excessive smoke from exhaust muffler...
Page 89: Cylinder And Piston
Cortesia de/ Courtesy of: www.batmotos.com . CYLINDER/PISTON DOWNTOWN 125i CYLINDER AND PISTON REMOVAL Remove the cylinder head (refer to “CYLINDER HEAD” section in the chapter Remove the water hose attached the cylinder. Remove the two cylinder bolts/washers (2). Remove the cylinder. Remove the cylinder gasket (4) and dowel pins (3).
Page 90 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . CYLINDER/PISTON Spread each piston ring and remove it by lifting up at a point opposite the gap ＊ Do not damage the piston ring by spreading the ends too far. Clean carbon deposits from the piston ring grooves.
Page 91 Cortesia de/ Courtesy of: www.batmotos.com . CYLINDER/PISTON DOWNTOWN 125i Piston/Piston pin Measure the piston O.D. at the point (A) from the bottom and 90° to the piston pin hole. 10 mm Service Limit: 15.04 mm (0.6016 in) Service Limit: 0.02 mm (0.0008 in) Cortesia de/ Courtesy of: www.batmotos.com...
Page 92 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . CYLINDER/PISTON Cylinder Check the cylinder for warpage with a straight edge and feeler gauge in the directions shown. Check the cylinder wall for wear or damage. Measure and record the cylinder I.D. at three levels in an X and Y axis.
Page 93 Cortesia de/ Courtesy of: www.batmotos.com . CYLINDER/PISTON DOWNTOWN 125i Intake Side Guide Inspect the exhaust side and intake side chain guides. Wear/Damage → Replace. Exhaust Side Guide INSTALLATION Piston ring Carefully install the piston rings into the piston ring grooves with the markings facing ＊...
Page 94 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . CYLINDER/PISTON Cylinder/Piston Clean any gasket material attached the cylinder mating surfaces of the crankcase and oil passage. Apply engine oil to the piston pin. Apply engine oil to the connecting rod small end and piston pin hole.
Page 95 Cortesia de/ Courtesy of: www.batmotos.com . CYLINDER/PISTON DOWNTOWN 125i Apply engine oil to the cylinder wall, piston and piston ring outer surfaces. Pass the cam chain through the cylinder and install the cylinder over the piston. ＊ Be careful not to damage the piston rings and cylinder walls.
Page 96: Drive And Driven Pulleys
Cortesia de/ Courtesy of: www.batmotos.com . DRIVE AND DRIVEN PULLEYS DOWNTOWN 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ DRIVE AND DRIVEN PULLEYS __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 8- 1 SERVICE INFORMATION------------------------------------------------ 8- 2 TROUBLESHOOTING----------------------------------------------------- 8- 3 LEFT CRANKCASE COVER --------------------------------------------- 8- 4 DRIVE PULLEY, DRIVE BELT AND DRIVEN PULLEY ---------- 8- 5 Cortesia de/ Courtesy of: www.batmotos.com...
Page 97: Schematic Drawing
Cortesia de/ Courtesy of: www.batmotos.com . DRIVE AND DRIVEN PULLEYS DOWNTOWN 125i SCHEMATIC DRAWING Cortesia de/ Courtesy of: www.batmotos.com...
Page 98: Service Information
Cortesia de/ Courtesy of: www.batmotos.com . DRIVE AND DRIVEN PULLEYS DOWNTOWN 125i SERVICE INFORMATION GENERAL INSTRUCTIONS • The drive pulley, clutch and driven pulley can be serviced with the engine installed. • Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley.
Page 99: Troubleshooting
Cortesia de/ Courtesy of: www.batmotos.com . DRIVE AND DRIVEN PULLEYS DOWNTOWN 125i TROUBLESHOOTING Engine starts but motorcycle fail to move Lack of power • Worn drive belt • Worn drive belt • Broken ramp plate • Weak driven face spring •...
Page 100: Left Crankcase Cover
Cortesia de/ Courtesy of: www.batmotos.com . DRIVE AND DRIVEN PULLEYS DOWNTOWN 125i LEFT CRANKCASE COVER REMOVAL Remove ten left crankcase cover bolts and then remove the left crankcase cover. Remove the gasket and dowel pins. Dowel Pins INSTALLATION Install the dowel pins and gasket. Install the left crankcase cover.
Page 101: Drive Pulley, Drive Belt And Driven Pulley
Cortesia de/ Courtesy of: www.batmotos.com . DRIVE AND DRIVEN PULLEYS DOWNTOWN 125i DRIVE PULLEY, DRIVE BELT AND DRIVEN PULLEY Nut/Ratchet REMOVAL Remove the left crankcase cover Use the special tool to hold the drive pulley, then remove the nut and ratchet. Special tool: Universal holder A120E00017...
Page 102 Cortesia de/ Courtesy of: www.batmotos.com . DRIVE AND DRIVEN PULLEYS DOWNTOWN 125i Remove the movable drive face assembly. Movable Drive Face Assembly Drive belt inspection Check the drive belt for cracks, separation or abnormal or excessive wear. Replace a new belt at every 20000KM ＊...
Page 103 Cortesia de/ Courtesy of: www.batmotos.com . DRIVE AND DRIVEN PULLEYS DOWNTOWN 125i Boss INSTALLATION Apply lubricant to the drive face boss inner surface, then install the movable drive face assembly. Movable Drive Face Assembly Clutch Outer/Driven Pulley Assembly Install the clutch outer onto the driven pulley assembly.
Page 104 Cortesia de/ Courtesy of: www.batmotos.com . DRIVE AND DRIVEN PULLEYS DOWNTOWN 125i Nut/Ratchet Install the drive pulley face and ratchet. Use the special tool to hold drive pulley face, then tighten the nut to the specified torque. Torque: DINK 200i: 5.8 kgf-m (58 N-m, 42 lbf-ft) 5.5~6.5 kgf-m (55~65 N-m) Special tool: Universal holder...
Page 105 Cortesia de/ Courtesy of: www.batmotos.com . DRIVE AND DRIVEN PULLEYS DOWNTOWN 125i DRIVE PULLEY DISASSEMBLY Remove the drive face boss. Boss Ramp Plate Remove the ramp plate Take out six weight rollers. Weight Roller Cortesia de/ Courtesy of: www.batmotos.com...
Page 106 Cortesia de/ Courtesy of: www.batmotos.com . DRIVE AND DRIVEN PULLEYS DOWNTOWN 125i DRIVE PULLEY INSPECTION Weight rollers Check each roller for wear or damage. Measure outside diameter. Service limit: 19.8 mm (0.792 in) Movable drive face/Slide pieces/Drive pulley face Ramp Plate Check the movable drive face splines for wear, cracks or damage.
Page 107 Cortesia de/ Courtesy of: www.batmotos.com . DRIVE AND DRIVEN PULLEYS DOWNTOWN 125i DRIVE PULLEY ASSEMBLY Clean the movable drive face, drive pulley face, weight rollers, slide pieces, ramp plate and drive face boss. ＊ Remove any excess grease. Install the weight rollers. ＊...
Page 108 Cortesia de/ Courtesy of: www.batmotos.com . DRIVE AND DRIVEN PULLEYS DOWNTOWN 125i Install the drive face boss. Boss 8-12 Cortesia de/ Courtesy of: www.batmotos.com...
Page 109 Cortesia de/ Courtesy of: www.batmotos.com . DRIVE AND DRIVEN PULLEYS DOWNTOWN 125i DRIVEN PULLEY DISASSEMBLY Lock Nut Wrench Hold the clutch/driven pulley assembly with the clutch spring compressor. ＊ Be sure to use a clutch spring compressor to avoid spring damage. Special tool: Clutch Spring Compressor A120E00034...
Page 110 Cortesia de/ Courtesy of: www.batmotos.com . DRIVE AND DRIVEN PULLEYS DOWNTOWN 125i Remove the spring. Remove the spring collar on the movable driven face. Remove the three guide pins/rollers, then remove the movable driven face. Remove the needle bearing from driven face. Remove the snap ring, then remove the bearing from driven face.
Page 111 Cortesia de/ Courtesy of: www.batmotos.com . DRIVE AND DRIVEN PULLEYS DOWNTOWN 125i DRIVEN PULLEY INSPECTION Grooves Check the driven pulley for smooth operation. If any scratches or damage is found then replace as a set. Check guide pins and rollers for wear or damage.
Page 112 Cortesia de/ Courtesy of: www.batmotos.com . DRIVE AND DRIVEN PULLEYS DOWNTOWN 125i DRIVEN PULLEY ASSEMBLY Clean any oil from the drive belt sliding surfaces on the driven face. Apply grease Filling 12 g of grease to driven face inner side. Apply grease to lips of the new dust seals and install into the movable driven face.
Page 113: Final Reduction
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i . FINAL REDUCTION __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 9-1 SERVICE INFORMATION------------------------------------------------ 9-2 TROUBLESHOOTING----------------------------------------------------- 9-2 FINAL REDUCTION ------------------------------------------------------- 9-3 BEARING REPLACEMENT ---------------------------------------------- 9-7 Cortesia de/ Courtesy of: www.batmotos.com...
Page 114: Final Reduction
Cortesia de/ Courtesy of: www.batmotos.com . FINAL REDUCTION DOWNTOWN 125 i SCHEMATIC DRAWING Cortesia de/ Courtesy of: www.batmotos.com...
Page 115: Service Information
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i . FINAL REDUCTION SERVICE INFORMATION GENERAL INSTRUCTIONS • The servicing operations of this section can be made with the engine installed. • When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation. SPECIFICATIONS Specified Oil: SAE 90# Oil Capacity:...
Page 116 Cortesia de/ Courtesy of: www.batmotos.com . FINAL REDUCTION DOWNTOWN 125 i FINAL REDUCTION REMOVAL Drain the transmission gear oil into a clean container (refer to the “TRANSMISSION OIL” section in the chapter 3). Remove the driven pulley (refer to the “DRIVE PULLEY, DRIVE BELT AND DRIVEN PULLEY”...
Page 117 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i . FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage. Inspect the final gear and final gear shaft for wear, damage or seizure. Check the driveshaft for wear or damage. Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage.
Page 118 Cortesia de/ Courtesy of: www.batmotos.com . FINAL REDUCTION DOWNTOWN 125 i Drive Shaft Bearing Check the transmission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage. Countershaft Bearing Final Shaft Bearing Final Gear Shaft Bearing Drive Shaft Bearing Countershaft Bearing...
Page 119 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i . FINAL REDUCTION Dowel pins Install new gasket. Install two dowel pins. Install the transmission case cover. Install and tighten the nine bolts to the specified torque in a crisscross pattern in 2 or 3 steps.
Page 120: Bearing Replacement
Cortesia de/ Courtesy of: www.batmotos.com . FINAL REDUCTION DOWNTOWN 125 i BEARING REPLACEMENT TRANSMISSION CASE COVER Remove the transmission case cover Remove the transmission case cover bearings by using the special tool. Special tool: Bearing puller A120E00037 Install the new bearings or new oil seal into the transmission case cover by using the special tool.
Page 121 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i . FINAL REDUCTION Install the new bearings or new oil seal into the transmission case by using the special tool. Special tool: Oil seal and bearing installer A120E00014 After installation, fill the transmission case with the specified oil.
Page 122: Generator/Starter Clutch
Cortesia de/ Courtesy of: www.batmotos.com . A.C. GENERATOR/STARTER CLUTCH DOWNTOWN 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ A.C. GENERATOR/STARTER CLUTCH __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 10-1 SERVICE INFORMATION------------------------------------------------ 10-2 TROUBLESHOOTING----------------------------------------------------- 10-2 ALTERNATOR STATOR-------------------------------------------------- 10-3 STARTER CLUTCH-------------------------------------------------------- 10-6 10-0 Cortesia de/ Courtesy of: www.batmotos.com...
Page 123 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . A.C. GENERATOR/STARTER CLUTCH SCHEMATIC DRAWING 10-1 Cortesia de/ Courtesy of: www.batmotos.com...
Page 124 Cortesia de/ Courtesy of: www.batmotos.com . A.C. GENERATOR/STARTER CLUTCH DOWNTOWN 125i SERVICE INFORMATION GENERAL INSTRUCTIONS • All servicing operations and inspections in this section can be made with the engine installed. • Drain the coolant before removing the right crankcase cover. •...
Page 125 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . A.C. GENERATOR/STARTER CLUTCH A.C.GENERATOR REMOVAL Drain the engine oil (refer to the “ENGINE OIL” section in the chapter 3). Disconnect the generator connectors Remove ten bolts attached the right crankcase cover and then remove the cover. Dowel Pins Remove two dowel pins and gasket.
Page 126 Cortesia de/ Courtesy of: www.batmotos.com . A.C. GENERATOR/STARTER CLUTCH DOWNTOWN 125i INSPECTION Check the stator and pulse coil for damage. Stator INSTALLATION Install the stator and tighten the stator mount bolts to the specified torque. Torque: 1 kgf-m Apply sealant to the grommet seating surface and install it to the cover groove properly.
Page 127 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . A.C. GENERATOR/STARTER CLUTCH Install the dowel pins and gasket. Install the right crankcase cover and tighten the bolts in a crisscross pattern in 2 or 3 steps. 10-5 Cortesia de/ Courtesy of: www.batmotos.com...
Page 128 Cortesia de/ Courtesy of: www.batmotos.com . A.C. GENERATOR/STARTER CLUTCH DOWNTOWN 125i STARTER CLUTCH REMVOAL Remove the right crankcase cover Hold the flywheel with a special tool and remove the flywheel nut. Special tool: Flywheel holder A120E00021 Flywheel Holder Flywheel Flywheel Puller Remove the flywheel by using the special tool.
Page 129 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . A.C. GENERATOR/STARTER CLUTCH Starter Driven Gear Remove the starter driven gear. INSPECTION Install the driven gear into the flywheel. Check the operation of the sprag clutch by turning the driven gear. You should be able to turn the driven gear clockwise smoothly, but the gear should not turn counterclockwise.
Page 130 Cortesia de/ Courtesy of: www.batmotos.com . A.C. GENERATOR/STARTER CLUTCH DOWNTOWN 125i INSTALLATION Starter Driven Gear Install the starter driven gear onto the crankshaft. Shaft Reduction Gear Apply oil to the starter reduction gear shaft. Install the starter reduction gear and shaft to the right crankcase.
Page 131 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125i . A.C. GENERATOR/STARTER CLUTCH Hold the flywheel with the special tool and tighten the flywheel nut. Torque: 5.0~6.0 kgf-m Special tool: Flywheel holder A120E00021 Flywheel Flywheel Holder Install the dowel pins and gasket. Install the right crankcase cover and tighten the bolts in a crisscross pattern in 2 or 3 steps.
Page 132: Crankcase/Crankshaft
Cortesia de/ Courtesy of: www.batmotos.com . CRANKCASE/CRANKSHAFT DOWNTOWN 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE/CRANKSHAFT __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 11-1 SERVICE INFORMATION------------------------------------------------ 11-2 TROUBLESHOOTING----------------------------------------------------- 11-2 CRANKCASE SEPARATION -------------------------------------------- 11-3 CRANKCASE ASSEMBLY ----------------------------------------------- 11-4 11-0 Cortesia de/ Courtesy of: www.batmotos.com...
Page 133: Crankcase/Crankshaft
Cortesia de/ Courtesy of: www.batmotos.com . CRANKCASE/CRANKSHAFT DOWNTOWN 125i SCHEMATIC DRAWING 11-1 Cortesia de/ Courtesy of: www.batmotos.com...
Page 134: Service Information
Cortesia de/ Courtesy of: www.batmotos.com . CRANKCASE/CRANKSHAFT DOWNTOWN 125i SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. • When separating the crankcase, never use a driver to pry the crankcase mating surfaces apart forcedly to prevent damaging the mating surfaces.
Page 135: Crankcase Separation
Cortesia de/ Courtesy of: www.batmotos.com . CRANKCASE/CRANKSHAFT DOWNTOWN 125i CRANKCASE SEPARATION Remove the two right crankcase attaching bolts. Bolt Bolts Remove the left crankcase bolts. Left Crankcase Place the crankcase with the left crankcase Right Crankcase down and remove the right crankcase from the left crankcase.
Page 136: Crankcase Assembly
Cortesia de/ Courtesy of: www.batmotos.com . CRANKCASE/CRANKSHAFT DOWNTOWN 125i Oil Seal Remove the oil seal from the left crankcase. Left Crankcase CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces. ＊ Avoid damaging the crankcase mating surfaces. Install a new oil seal into the left crankcase.
Page 137 Cortesia de/ Courtesy of: www.batmotos.com . CRANKCASE/CRANKSHAFT DOWNTOWN 125i Place the left crankcase down and install the crankshaft into the left crankcase. ＊ • Avoid damaging the oil seal. • Apply grease to the lip of the oil seal. Change a new gasket. Bolts Place into the crankshaft and onto the left crankcase.
Page 138 Cortesia de/ Courtesy of: www.batmotos.com . CRANKCASE/CRANKSHAFT DOWNTOWN 125i Cam Chain Tensioner Slipper Install the cam chain. Install the cam chain tensioner slipper. Install and tighten the cam chain tensioner slipper bolt. Torque: 1.0kgf-m Bolt 11-6 Cortesia de/ Courtesy of: www.batmotos.com...
Page 139: Cooling System
Cortesia de/ Courtesy of: www.batmotos.com . COOLING SYSTEM Downtown 125 i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 12- 1 TROUBLESHOOTING----------------------------------------------------- 12- 1 COOLING SYSTEM TESTING------------------------------------------- 12- 3 COOLANT REPLACEMENT --------------------------------------------- 12- 4 RADIATOR ------------------------------------------------------------------ 12- 7 FAN MOTOR ---------------------------------------------------------------- 12- 9 FAN MOTOR SWITCH ---------------------------------------------------- 12-10 WATER PUMP -------------------------------------------------------------- 12-11...
Page 140: Cooling System Testing
Cortesia de/ Courtesy of: www.batmotos.com . COOLING SYSTEM Downtown 125 i SERVICE INFORMATION GENERAL INSTRUCTIONS • The water pump must be serviced after removing the engine. Other cooling system service can be done with the engine installed in the frame. •...
Page 141 1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.067 1.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1.071 COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS) Freezing Point Mixing Rate KYMCO SIGMA Coolant Concentrate Distilled Water -9℃ -15℃ -25℃ -37℃...
Page 142 Cortesia de/ Courtesy of: www.batmotos.com . COOLING SYSTEM Downtown 125 i COOLING SYSTEM TESTING RADIATOR CAP INSPECTION ＊ Removing the radiator cap while the engine is hot can cause the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap.
Page 143: Coolant Replacement
Cortesia de/ Courtesy of: www.batmotos.com . COOLING SYSTEM Downtown 125 i COOLANT REPLACEMENT PREPARATION ● The effectiveness of coolant decreases with the accumulation of rest or if there is a change in the mixing proportion during usage. Therefore, best performance change coolant regularly as specified in he maintenance...
Page 144 Cortesia de/ Courtesy of: www.batmotos.com . COOLING SYSTEM Downtown 125 i Remove the screw (3) and reserve tank lid (4). Remove the reserve tank cap (5) and drain the coolant from the reserve tank. Reinstall and tighten the drain bolt securely.
Page 145 Cortesia de/ Courtesy of: www.batmotos.com . COOLING SYSTEM Downtown 125 i Fill the system with the recommended coolant through the filler opening up to the filler neck (1). Bleed air from the system as follow: 1. Start the engine and let it idle for 2−3 minutes.
Page 146: Radiator
Cortesia de/ Courtesy of: www.batmotos.com . COOLING SYSTEM Downtown 125 i RADIATOR REMOVAL Drain the coolant. Disconnect the siphon hose (1) and air bleed hose (2). Remove the nut(3). Loosen the hose bands, then disconnect the input radiator hose (4) and output radiator hose (5) from the radiator.
Page 147 Cortesia de/ Courtesy of: www.batmotos.com . COOLING SYSTEM Downtown 125 i Remove three nuts (10) and then remove the radiator from frame. INSTALLATION Installation is in the reverse order of removal. Refill the coolant (10) 12-8 Cortesia de/ Courtesy of: www.batmotos.com...
Page 148: Fan Motor
Cortesia de/ Courtesy of: www.batmotos.com . COOLING SYSTEM Downtown 125 i FAN MOTOR REMOVAL Remove the radiator Remove the three mounting bolts (1) and then remove the fan motor (2) INSPECTION Battery Check the fan motor to operate using an available battery.
Page 149 Cortesia de/ Courtesy of: www.batmotos.com . COOLING SYSTEM Downtown 125 i FAN MOTOR SWITCH REMOVAL Disconnect the fan motor switch connectors Remove the thermostat(1). INSPECTION Place the thermal switch in the stove with water as shown and raise the water temperature gradually to check for the temperature at which the starts to operate.
Page 150: Water Pump
Cortesia de/ Courtesy of: www.batmotos.com . COOLING SYSTEM Downtown 125 i Right Crankcase Cover WATER PUMP MECHANICAL SEAL (WATER SEAL) INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage. If the mechanical seal is leaking, remove the right crankcase cover and replace the mechanical seal.
Page 151 Cortesia de/ Courtesy of: www.batmotos.com . COOLING SYSTEM Downtown 125 i Bolts Water Pump Cover Remove four bolts and the water pump cover, gasket and two dowel pins. Impeller (Left Hand Threads) Remove the water pump impeller. ＊ The impeller has left hand threads. Seal Washer (Porcelain) Mechanical Seal Inspect the mechanical (water) seal and seal...
Page 152 Cortesia de/ Courtesy of: www.batmotos.com . COOLING SYSTEM Downtown 125 i WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover. Remove five bolts attaching the water pump assembly. Remove the water pump assembly, gasket and dowel pins. Water Pump Shaft Remove the water pump shaft clip and water pump shaft...
Page 153 Cortesia de/ Courtesy of: www.batmotos.com . COOLING SYSTEM Downtown 125 i Water Pump Assembly Install the dowel pins and a new gasket and then install the water pump assembly to the right crankcase cover. Tighten five bolts to secure the water pump assembly.
Page 154 Cortesia de/ Courtesy of: www.batmotos.com . COOLING SYSTEM Downtown 125 i Impeller (Left Hand Threads) Install the impeller onto the water pump shaft. Torque: 1.2 kgf-m (12 N-m, 9 lbf-ft) ＊ The impeller is with left hand threads. Dowel Pins Install two dowel pins and a new gasket.
Page 155: Water Temperature Sensor
Cortesia de/ Courtesy of: www.batmotos.com . COOLING SYSTEM Downtown 125 i WATER TEMPERATURE SENSOR REMOVAL Remove the luggage box Drain the coolant Disconnect the water temperature sensor connectors (1). Remove the water temperature sensor (2) from thermostat. INSPECTION Sensor Connect the water temperature sensor to the ohmmeter and dip it in water contained in a pan which is placed on an electric heater.
Page 156 Cortesia de/ Courtesy of: www.batmotos.com . COOLING SYSTEM Downtown 125 i INSTALLATION Tighten the water temperature sensor. Torque: 0.8 kgf-m (8 N-m, 5.8 lbf-ft) Connect the sensor connectors. After the water temperature sensor has been installed, fill coolant and perform air bleeding .
Page 157: Thermostat
Cortesia de/ Courtesy of: www.batmotos.com . COOLING SYSTEM Downtown 125 i THERMOSTAT THERMOSTAT REMOVAL REMOVAL Drain the coolant Remove the luggage box Bolts Disconnect the water hose (1) from the thermostat housing. Remove the mounting bolt (2) and the thermostat housing attaching the cylinder head.
Page 158 Cortesia de/ Courtesy of: www.batmotos.com . COOLING SYSTEM Downtown 125 i Screws DISASSEMBLY Remove two screws and separate the thermostat housing halves. Thermostat Thermostat Remove the thermostat from the thermostat housing. 12-19 Cortesia de/ Courtesy of: www.batmotos.com...
Page 159 Cortesia de/ Courtesy of: www.batmotos.com . COOLING SYSTEM Downtown 125 i INSPECTION Suspend the thermostat in a pan of water over a burner and gradually raise the water Thermostat temperature to check its operation. Technical Data Thermometer 71 ± 1.5°C Begins to open Full-open 80°C...
Page 160: 13. Fi Diagnostic Tool Operation
Cortesia de/ Courtesy of: www.batmotos.com 13. Fi DIAGNOSTIC TOOL OPERATION DOWN TOWN 125i Fi Diagnostic Tool Operation Instructions Part No. 3620A-LEB2-E00 KEY FUNCTION Model No. DATAAnalyze Down Button DTC Inspect DTC indicator(Failure codes) ECU Version Enter or Exit Power indicator UP Button Adjust(TPI andABV reset function) 13-0...
Page 161 Cortesia de/ Courtesy of: www.batmotos.com 13. Fi DIAGNOSTIC TOOL OPERATION DOWN TOWN 125i Fi diagnostic tool Outlook Fi diagnostic tool Outlook......13-0 Adjust............13-8 Diagnostic Standard Specifications ..13-9 DTC Inspection Precedure DTC Inspection Precedure ........13-2 Diagnostic Standard Specifications ............13-5 DTC Clear Procedure DTC Clear Procedure 13-6 Data Analysis...
Page 162 Cortesia de/ Courtesy of: www.batmotos.com 13. Fi DIAGNOSTIC TOOL OPERATION DOWN TOWN 125i DTC INSPECTION PROCEDURE Diagnostic Tool Connector Connect Fi diagnostic tool with the connector of harness wire located beside the Battery. Press the " Enter " button Check the software version Press the "...
Page 163 Cortesia de/ Courtesy of: www.batmotos.com 13. Fi DIAGNOSTIC TOOL OPERATION DOWN TOWN 125i Press the " Enter " button to check the DTC number Press the " Enter " button Press the " Enter " button Display what's DTC number on this DTC-List. Refer to DTC summary list.
Page 164 Cortesia de/ Courtesy of: www.batmotos.com 13. Fi DIAGNOSTIC TOOL OPERATION DOWN TOWN 125i Press the " UP " button Press the " Enter " button and then turn to the previous page. Press the " UP " button Press the " Enter " button and then turn to the first page.
Page 165: Dtc Clear Procedure
Cortesia de/ Courtesy of: www.batmotos.com 13. Fi DIAGNOSTIC TOOL OPERATION DOWN TOWN 125i DTC CLEAR PROCEDURE Choose " Load DTC " Press the " Down " button Press the " Enter " button The DTC indicator is lighting at that time. Clearing DTC completed until the DTC indicator is off.
Page 166: Data Analysis
Cortesia de/ Courtesy of: www.batmotos.com 13. Fi DIAGNOSTIC TOOL OPERATION DOWN TOWN 125i DATA ANALYSIS Choose " Data Analyze " Press the " Enter " button to enter page 01. The figure includes engine speed, idle speed setpoint and battery voltage. Refer to standard specifications .
Page 167 Cortesia de/ Courtesy of: www.batmotos.com 13. Fi DIAGNOSTIC TOOL OPERATION DOWN TOWN 125i The figure includes fuel injector interval, ignition advance angle andABV angle. Refer to standard specifications . Press the " Down " button to enter page 05. The figure includes O2 sensor voltage, O2 heater working condition and O2 correction.
Page 168: Adjust
Cortesia de/ Courtesy of: www.batmotos.com 13. Fi DIAGNOSTIC TOOL OPERATION DOWN TOWN 125i ADJUST Need to make TPI/ABV reset to operate after changing new ECU and clean THROTTLE BODY and changing the engine department product, let ECU set up and set up initially Choose "Adjust "...
Page 169: Diagnostic Standard Specifications
Cortesia de/ Courtesy of: www.batmotos.com 13. Fi DIAGNOSTIC TOOL OPERATION DOWN TOWN 125i Diagnostic Standard Specifications Diagnostic Standard Specifications Reasonofrepair: □maintenance □breakdown Item Mem o Date Reference ECUNo LFA7 Hardware V er Software V er Calibration V er ModelNam e Active Occurred History...
Page 170: Fuel Injection System
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i FUEL SYSTEM (Auto Control Fuel Injection System) FUEL SYSTEM (Auto Control Fuel Injection System) SYSTEM DIAGRAM ................14-1 SYSTEM LOCATION................. 14-2 SERVICE INFORMATION ............... 14-3 TROUBLESHOOTING............... 14-4 CHECK ENGINE LAMP (CELP) ............. 14-5 HOW TO SHOW THE FAILURE CODE ........
Page 171 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i FUEL SYSTEM (Auto Control Fuel Injection System) SYSTEM DIAGRAM KEY ON FUEL PUMP ROLL T-MAP Voltage 曲軸感知器曲軸感知器進氣壓力及感知器含氧(O2) 大氣壓力感感知器知器 INDUCTIVE INJECTOR 進氣壓力及大氣壓力感知器 IGNITION COIL 感知器 KEY OFF 14-1 Cortesia de/ Courtesy of: www.batmotos.com...
Page 172: System Location
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i FUEL SYSTEM (Auto Control Fuel Injection System) SYSTEM LOCATION 01: Inductive ignition coil 02: Fuel pump 03: ECU 04: Fuel injector 05: WTS sensor 06: T-MAP sensor 07: ABV 08: TPS 09: Roll sensor(Angle detect sensor) 10: CPS 11: O2/O2 HT sensor 14-2...
Page 173: Service Information
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i FUEL SYSTEM (Auto Control Fuel Injection System) SERVICE INFORMATION GENERAL INSTRUCTIONS ＊ Gasoline is very dangerous. When working with gasoline, keep sparks and flames away from the working area. Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in a well-ventilated area.
Page 174: Troubleshooting
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i FUEL SYSTEM (Auto Control Fuel Injection System) TROUBLESHOOTING Engine won’t start Backfiring or misfiring during acceleration • Battery voltage too low • Ignition system malfunction • Fuel level too low • Pinched or clogged fuel hose Poor performance (drive ability) and poor •...
Page 175: Check Engine Lamp (Celp)
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i FUEL SYSTEM (Auto Control Fuel Injection System) CHECK ENGINE LAMP (CELP) When turning on the switch, the lamp will be lighted for 2 seconds then off. Let user to know the lamp is available and connect to ECU.
Page 176: How To Show The Failure Code
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i FUEL SYSTEM (Auto Control Fuel Injection System) How To Show Failure Code You can read the failure code by as below : Turn switch on. The CELP will be lighted for 2 seconds then off. The CELP start to blink to show the failure codes (The number of blinks from 1 to 25).
Page 177: Celp Failure Codes Chart
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i FUEL SYSTEM (Auto Control Fuel Injection System) CELP Failure Code Chart(1) Blink Failure Fault Priority Fault management Codes description P0217 Engine 1.Slow down the vehicle and go to workshop for temperature checking immediately. overheat 2.Confirm if the engine temperature sensor or electric circuit is abnormality.
Page 178 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i FUEL SYSTEM (Auto Control Fuel Injection System) CELP Failure Code Chart(2) Blink Failure Fault description Priority Fault management Codes P1122 Throttle position sensor 1.Make sure if the connector of Throttle position sensor is connected correctly.
Page 179 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i FUEL SYSTEM (Auto Control Fuel Injection System) CELP Failure Code Chart(3) Blink Failure Fault description Priority Fault management Codes 1. Check if the connector of ignition coil is loosen. P0350 Ignition coil or electric 2.
Page 180 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i FUEL SYSTEM (Auto Control Fuel Injection System) CELP Failure Code Chart(4) Blink Failure Fault description Priority Fault management Codes P0650 CELP electric circuit 1. Check if the lamp of CELP is broken. 2.
Page 181: Maintaining By Checking Component
Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i FUEL SYSTEM (Auto Control Fuel Injection System) Maintaining By Checking Component ECU(Engine Control Unit) Outlook checking Voltage inspection Connect the meter (+) probe to the F4(R/W)wire and the meter (-) probe to the H4(G/B) wire to measure the voltage.
Page 182 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i FUEL SYSTEM (Auto Control Fuel Injection System) FUEL PUMP Connect the meter (+) probe to the red/black wire and the meter (-) probe to the green wire to measure the voltage from the ECU input to fuel pump unit.
Page 183 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i FUEL SYSTEM (Auto Control Fuel Injection System) T-MAP(Manifold Air Temperature Pressure) Sensor Connect the PDA or KYMCO Fi diagnostic tool. Into the Data Analyze item . Check if the manifold pressure data malfunction.
Page 184 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i FUEL SYSTEM (Auto Control Fuel Injection System) WTS (Water Temperature Sensor) Connect the meter (+) probe to the V/G wire and the meter (-) probe to the G/L wire to measure the voltage Standard : 5±0.25 V Measure the resistance of the WTS Standard (20°C/68°F ): 2.075±10%kΩ...
Page 185 Measure the resistance of the O2 sensor heater. (2 white wire pin) Standard (20°C/68°F ): 6.7 ~9.5Ω Connect the PDA or KYMCO Fi diagnostic tool. Into the Data Analyze item . Check Page 05 (Key switch ON then start engine...
Page 186: Maintaining Special Notice
Standard: Normal: 0.4~1.4V OVER 65°: 3.7~4.4 V Maintaining Special Notice Never adjust those two TP screws, those were adjusted to be the best condition by KYMCO, if change this condition it may cause instable riding. TP screws 14-16 Cortesia de/ Courtesy of: www.batmotos.com...
Page 187 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i FUEL SYSTEM (Auto Control Fuel Injection System) Connect the PDA or KYMCO Fi diagnostic tool. Into the Data Analyze item . Check ignition advance data malfunction. (Key switch is ON then start engine until 80 ° C) 20 °...
Page 188 Cortesia de/ Courtesy of: www.batmotos.com DOWNTOWN 125 i FUEL SYSTEM (Auto Control Fuel Injection System) DOWNTOWN 125 i SF： Customer： Eng.Num： Date of Date of Mileage： production repair： Reason of repair: □ maintenance □ breakdown Item Memo Date Reference LFA7 ECU No Hardware Ver Software Ver...
Page 189: Handlebar/Front Wheel/Front Brake/Front Shock Absorber/Steering Stem
Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125 i FRONT SHOCK ABSORBER/STEERING STEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 15- 1 TROUBLESHOOTING----------------------------------------------------- 15- 2 HANDLEBAR --------------------------------------------------------------- 15- 3 FRONT WHEEL------------------------------------------------------------- 15- 7 FRONT BRAKE FLUID---------------------------------------------------- 15-11 FRONT BRAKE PAD ------------------------------------------------------ 15-15 BRAKE DISC INSPECTION ---------------------------------------------- 15-17...
Page 190: Service Information
Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125i FRONT SHOCK ABSORBER/STEERING STEM SERVICE INFORMATION GENERAL INSTRUCTIONS • Remove the motorcycle frame covers before removing the front wheel, steering handlebar, front shock absorber and front fork. Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down.
Page 191: Troubleshooting
Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125 i FRONT SHOCK ABSORBER/STEERING STEM TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling • Excessively tightened steering stem top • Bent rim • Loose front axle cone race • Broken steering balls •...
Page 192: Handlebar
Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125i FRONT SHOCK ABSORBER/STEERING STEM HANDLEBAR REMOVAL Remove the lower handlebar cover and front cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Remove the two bolts (1) and disconnect the brake light switch wire (2), then remove the rear brake master cylinder.
Page 193 Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125 i FRONT SHOCK ABSORBER/STEERING STEM INSTALLATION Install the handlebar onto the steering stem and install the handlebar collar, lock nut and bolt. Tighten the bolt to the specified torque. Torque: 4.5 kgf-m (45 N-m, 32 lbf-ft) Install the front and rear master cylinders and connect the brake light switch wires 15-4...
Page 194 Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125i FRONT SHOCK ABSORBER/STEERING STEM DISASSEMBLY Remove two screws (1) attaching right handlebar switch. Disconnect the throttle cable (2) attaching the throttle grip. Remove the right headlight switch. Remove two screws (3) and then remove the turn light switch.
Page 195 Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125 i FRONT SHOCK ABSORBER/STEERING STEM ASSEMBLY Install the turn light switch. ＊ Align the pin on the turn light switch with the hole on the handlebar. Install the headlight switch. ＊...
Page 196: Front Wheel
Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125i FRONT SHOCK ABSORBER/STEERING STEM FRONT WHEEL REMOVAL Jack the scooter front wheel off the ground. Remove the bolt , then pull out the axle . Remove the front wheel and collar. 15-7 Cortesia de/ Courtesy of: www.batmotos.com...
Page 197 Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125 i FRONT SHOCK ABSORBER/STEERING STEM INSTALLATION Apply grease to the collar (1), then install the collar onto the wheel. Install the speedometer speed wheel sensor(2) 15-8 Cortesia de/ Courtesy of: www.batmotos.com...
Page 198 Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125i FRONT SHOCK ABSORBER/STEERING STEM DISASSEMBLY Remove the side collar (1) and dust seal (2). Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly. Also check if the outer race fits tightly in the hub.
Page 199 Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125 i FRONT SHOCK ABSORBER/STEERING STEM Remove the front wheel bearing (5) by using the special tool. Special tool: Bearing puller A120E00037 ASSEMBLY Install the front wheel bearing (5) by using the special tool.
Page 200: Front Brake Fluid
Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125i FRONT SHOCK ABSORBER/STEERING STEM FRONT BRAKE FLUID FLUID REPLACEMENT/AIR BLEEDING ＊ ● A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent.
Page 201 Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125 i FRONT SHOCK ABSORBER/STEERING STEM Brake fluid draining Make sure that the master cylinder parallel to the ground, before removing the reservoir cover. Remove the two screws (1). Remove the reservoir cover , diaphragm plate and diaphragm .
Page 202 Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125i FRONT SHOCK ABSORBER/STEERING STEM Loosen the bleed valve and pump the brake lever. Stop operating the brake when no more fluid flows out of the bleed valve. Brake fluid filling/Air bleeding ＊...
Page 203 Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125 i FRONT SHOCK ABSORBER/STEERING STEM If the brake bleeder is not available, perform the following procedure. Pump up the system pressure with the brake lever until these are not air bubbles in the fluid flowing out of the reservoir small hole and lever resistance is felt.
Page 204: Front Brake Pad
Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125i FRONT SHOCK ABSORBER/STEERING STEM FRONT BRAKE PAD BRAKE PAD REPLACEMENT Remove the pad pins (1). Remove two caliper mounting bolts (2), then remove the caliper. Remove the brake pads(3). ＊ Always replace the brake pads in pairs to ensure even disc pressure.
Page 205 Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125 i FRONT SHOCK ABSORBER/STEERING STEM Install new pads so that their ends rest on the pad retainer on the brake properly. Install the pad pin by pushing the pads against the pad spring to align the pad pin holes in the pads and caliper.
Page 206: Brake Disc Inspection
Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125i FRONT SHOCK ABSORBER/STEERING STEM BRAKE DISC INSPECTION Visually inspect the brake disc for damage or cracks. Measure the brake disc thickness. Service limits: 3 mm (0.12 in) 15-17 Cortesia de/ Courtesy of: www.batmotos.com...
Page 207: Front Shock Absorber
Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125 i FRONT SHOCK ABSORBER/STEERING STEM FRONT SHOCK ABSORBER REMOVAL Remove the front cover and front fender. ( refer “FRAME CVOERS REMOVAL/INSTALLATION” section in the chapter 2 ). Remove the front brake caliper Remove the front wheel Remove the speed wheel sensor bolt (1) and then remove the brake hose guide from right...
Page 208 Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125i FRONT SHOCK ABSORBER/STEERING STEM REMOVAL Remove the steering handlebar Remove the front shock absorber Remove the front brake hose and speed wheel Sensor connector Hold the steering stem top cone race and remove the steering stem lock nut by using the special tool.
Page 209 Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125 i FRONT SHOCK ABSORBER/STEERING STEM Ball Inspect the ball races, cone races and steel balls for wear or damage. Replace if necessary. Remove the top balls. Remove the upper ball race by using a chisel if necessary.
Page 210 Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125i FRONT SHOCK ABSORBER/STEERING STEM INSTALLATION Install the new bottom cone race onto the steering stem. Install the new upper and bottom ball races into the frame. Apply grease to the top and bottom ball races and install new steel balls on the top ball race and new steel balls on the bottom ball race.
Page 211 Cortesia de/ Courtesy of: www.batmotos.com 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ Downtown 125 i FRONT SHOCK ABSORBER/STEERING STEM Top Ball Cone Race special tool Remove Bottom Ball Race special tool Remove Bottom Ball Race Top Ball Cone Race special tool special tool Install Install 15-22 Cortesia de/ Courtesy of: www.batmotos.com...
Page 212: 16. Rear Brake/Rear Fork/Rear
Cortesia de/ Courtesy of: www.batmotos.com 16. REAR BRAKE/REAR FORK/REAR DOWNTOWN 125i WHEEL/REAR SHOCK ABSORBER ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ REAR BRAKE/REAR FORK/REAR WHEEL/ REAR SHOCK ABSORBER _________________________________________________________________________________________ SCHEMATIC DRAWING --------------------------------------------------------------- 16-1 SERVICE INFORMATION-------------------------------------------------------------- 16-2 TROUBLESHOOTING------------------------------------------------------------------- 16-2 REAR BRAKE ----------------------------------------------------------------------------- 16-3 REAR FORK ------------------------------------------------------------------------------- 16-6 REAR WHEEL----------------------------------------------------------------------------- 16-7 REAR SHOCK ABSORBER ------------------------------------------------------------ 16-7...
Page 213 Cortesia de/ Courtesy of: www.batmotos.com 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DOWNTOWN 125i SCHEMATIC DRAWING 16-1 Cortesia de/ Courtesy of: www.batmotos.com...
Page 214 Cortesia de/ Courtesy of: www.batmotos.com 16. REAR BRAKE/REAR FORK/REAR DOWNTOWN 125i WHEEL/REAR SHOCK ABSORBER SERVICE INFORMATION GENERAL INSTRUCTIONS • When performing the services stated in this section, the engine and exhaust muffler must be cold to avoid scalding. • During servicing, keep oil or grease off the brake pads and brake disk. SPECIFICATIONS Item Standard (mm)
Page 215 Cortesia de/ Courtesy of: www.batmotos.com 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DOWNTOWN 125i REAR BRAKE Fluid Tube Bolt REAR BRAKE CALIPER REMOVAL First remove the exhaust muffler. Remove the rear brake fluid tube bolt and disconnect the brake fluid tube. Remove two bolts attaching the rear brake caliper.
Page 216 Cortesia de/ Courtesy of: www.batmotos.com 16. REAR BRAKE/REAR FORK/REAR DOWNTOWN 125 i WHEEL/REAR SHOCK ABSORBER Compressed Air Remove the piston from the brake caliper. If necessary, use compressed air to squeeze out the piston through the brake fluid inlet opening and place a towel under the caliper to avoid contamination caused by the removed piston.
Page 217 Cortesia de/ Courtesy of: www.batmotos.com 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DOWNTOWN 125i ASSEMBLY Spring Plate Install the two spring plates onto the groove of the caliper. ＊ Caliper Inside Make sure the spring plate next to the brake pad dowel pin orientation.
Page 218 Cortesia de/ Courtesy of: www.batmotos.com 16. REAR BRAKE/REAR FORK/REAR DOWNTOWN 125 i WHEEL/REAR SHOCK ABSORBER Fluid Tube Bolt INSTALLATION Install the brake caliper to the rear fork and tighten the two bolts. Torque: 27 N-m Connect the brake fluid tube to the brake caliper and install fluid tube bolt, copper washers and tighten the fluid tube bolt.
Page 219 Cortesia de/ Courtesy of: www.batmotos.com 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DOWNTOWN 125i REAR WHEEL REMOVAL Remove the exhaust muffler. Remove the rear brake caliper. Remove the rear fork. Remove the rear axle collar. INSTALLATION Remove the rear wheel. Install the rear shock absorbers in the reverse Rear Brake Disk Rear Axle Collar...
Page 220 Cortesia de/ Courtesy of: www.batmotos.com 16. REAR BRAKE/REAR FORK/REAR DOWNTOWN 125 i WHEEL/REAR SHOCK ABSORBER INSTALLATION Install the rear suspension in the reverse order of removal. Torque: Upper Mount Bolt: 40 N-m Lower Mount Bolt: 40 N-m 16-8 Cortesia de/ Courtesy of: www.batmotos.com...
Page 221: Battery/Charging System
Cortesia de/ Courtesy of: www.batmotos.com . BATTERY/CHARGING SYSTEM DOWNTOWN 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY/CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT ---------------------------------------- 17-1 CHARGING CIRCUIT ----------------------------------------------------- 17-1 SERVICE INFORMATION------------------------------------------------ 17-2 TROUBLESHOOTING----------------------------------------------------- 17-3 BATTERY -------------------------------------------------------------------- 17-4 CHARGING VOLTAGE INSPECTION -------------------------------- 17-6 REGULATOR/RECTIFIER ----------------------------------------------- 17-7 17-0 Cortesia de/ Courtesy of: www.batmotos.com...
Page 222 Cortesia de/ Courtesy of: www.batmotos.com . BATTERY/CHARGING SYSTEM DOWNTOWN125i CHARGING SYSTEM LAYOUT REGULATOR/RECTIFIER BATTERY 17-1 Cortesia de/ Courtesy of: www.batmotos.com...
Page 223 Cortesia de/ Courtesy of: www.batmotos.com . BATTERY/CHARGING SYSTEM DOWNTOWN 125i SERVICE INFORMATION GENERAL INSTRUCTIONS ＊ The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and eyes. Avoid contact with skin, eyes, or clothing. In case of contact, flush with water and get prompt medical attention •...
Page 224 Cortesia de/ Courtesy of: www.batmotos.com . BATTERY/CHARGING SYSTEM DOWNTOWN125i TROUBLESHOOTING No power Intermittent power • Dead battery • Loose battery cable connection • Disconnected battery cable • Loose charging system connection • Fuse burned out • Loose connection or short circuit in •...
Page 225 Cortesia de/ Courtesy of: www.batmotos.com . BATTERY/CHARGING SYSTEM DOWNTOWN 125i BATTERY REMOVAL/INSTALLATION The battery is in the battery box behind seat. 1. Remove the seat. 2. Remove the met-in box 3. Remove four screws and then remove the battery retainer 4.
Page 226 Cortesia de/ Courtesy of: www.batmotos.com . BATTERY/CHARGING SYSTEM DOWNTOWN125i VOLTAGE INSPECTION Remove the battery cover . Measure the battery voltage using a commercially available digital multimeter. Voltage (20ºC/68ºC): Fully charged: 13－13.2 V Insufficient charged: below 12.3 V BATTERY CHARGING Remove the battery Connect the charger positive (+) cable to the battery positive (+) terminal.
Page 227 Cortesia de/ Courtesy of: www.batmotos.com . BATTERY/CHARGING SYSTEM DOWNTOWN 125i CHARGING VOLTAGE INSPECTION Be sure that the battery is in good condition before performing this test. ＊ Do not disconnect the battery or any cable in the charging system without first switching off the ignition switch.
Page 228 Cortesia de/ Courtesy of: www.batmotos.com . BATTERY/CHARGING SYSTEM DOWNTOWN125i REGULATOR/RECTIFIER WIRE HARNESS INSPECTION Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect the regulator/rectifier connectors (1). Check the connector for loose contacts of corroded terminals.
Page 229 Cortesia de/ Courtesy of: www.batmotos.com . BATTERY/CHARGING SYSTEM DOWNTOWN 125i Check the continuity between the Green wire terminal and ground. There should be continuity at all times. Measure the resistance between each Yellow wire terminals. Standard: 0.4－0.6 Ω (20ºC/68ºF) Disconnect the regulator/rectifier connector. Check for continuity between each Yellow wire terminal regulator/rectifier side and ground.
Page 230 Cortesia de/ Courtesy of: www.batmotos.com . BATTERY/CHARGING SYSTEM DOWNTOWN125i REMOVAL/INSTALLATION Remove the body cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect the regulator/rectifier connectors (1). Remove the two bolts (2), attaching regulator/rectifier (3). Installation is in the reverse order of removal. 17-9 Cortesia de/ Courtesy of: www.batmotos.com...
Page 231: Ignition System
Cortesia de/ Courtesy of: www.batmotos.com . IGNITION SYSTEM DOWNTOWN 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM __________________________________________________________________________________ IGNITION SYSTEM LAYOUT ------------------------------------------ 18-1 SERVICE INFORMATION------------------------------------------------ 18-2 TROUBLESHOOTING----------------------------------------------------- 18-3 IGNITION COIL INSPECTION ------------------------------------------ 18-4 18-0 Cortesia de/ Courtesy of: www.batmotos.com...
Page 232 Cortesia de/ Courtesy of: www.batmotos.com . IGNITION SYSTEM DOWNTOWN 125 i IGNITION SYSTEM LAYOUT Roll sensor Ignition coil 18-1 Cortesia de/ Courtesy of: www.batmotos.com...
Page 233 Cortesia de/ Courtesy of: www.batmotos.com . IGNITION SYSTEM DOWNTOWN 125i SERVICE INFORMATION GENERAL INSTRUCTIONS Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is “ON” and current is present. ● When servicing the ignition system, always follow the steps in the troubleshooting.. ●...
Page 234 Cortesia de/ Courtesy of: www.batmotos.com . IGNITION SYSTEM DOWNTOWN 125 i TROUBLESHOOTING LOW PEAK VOLTAGE ● Cranking speed is too low (battery is undercharged). ● Poorly connected connectors or an open circuit in the ignition system. ● Faulty ignition-coil. ● Faulty ignition control module. NO PEAK VOLTAGE ●...
Page 235 Cortesia de/ Courtesy of: www.batmotos.com . IGNITION SYSTEM DOWNTOWN 125i IGNITION COIL INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE Remove the body cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Check cylinder compression and check that the spark plug (1) is installed correctly in the cylinder.
Page 236 Cortesia de/ Courtesy of: www.batmotos.com . IGNITION SYSTEM DOWNTOWN 125 i IGNITION PULSE GENERATOR INSPECTION Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect the ignition pulse generator connector (1). Measure the pulse generator resistance between the Green/White wire and Blue/Yellow wire.
Page 237 Cortesia de/ Courtesy of: www.batmotos.com . IGNITION SYSTEM DOWNTOWN 125i IGNITION COIL REMOVAL/INSTALLATION Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect the spark plug cap attaching the spark plug (1). Disconnect the ignition coil connector (2). Remove two bolts (3) attaching the ignition coil (4).
Page 238: Starting System
Cortesia de/ Courtesy of: www.batmotos.com . STARTING SYSTEM DOWNTOWN 125 i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STARTING SYSTEM __________________________________________________________________________________ STARTING SYSTEM LAYOUT ----------------------------------------- 19-1 STARTING CIRCUIT ------------------------------------------------------ 19-1 SERVICE INFORMATION------------------------------------------------ 19-2 TROUBLESHOOTING----------------------------------------------------- 19-2 STARTER MOTOR --------------------------------------------------------- 19-3 STARTER RELAY INSPECTION---------------------------------------- 19-5 19-0 Cortesia de/ Courtesy of: www.batmotos.com...
Page 239 Cortesia de/ Courtesy of: www.batmotos.com . STARTING SYSTEM DOWNTOWN 125 i STARTING SYSTEM LAYOUT Battery Start relay Start motor 19-1 Cortesia de/ Courtesy of: www.batmotos.com...
Page 240 Cortesia de/ Courtesy of: www.batmotos.com . STARTING SYSTEM DOWNTOWN 125 i SERVICE INFORMATION GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed. • After the starter clutch is installed, be sure to add the engine oil and coolant and then bleed air from the cooling system.
Page 241 Cortesia de/ Courtesy of: www.batmotos.com . STARTING SYSTEM DOWNTOWN 125 i STARTER MOTOR INSPECTION Disconnect the starter motor cable ( 2) from the start relay(1). Connect the start motor cable directly to the battery positive terminal (3). If the starter motor fail to work, the starter motor is faulty.
Page 242 Cortesia de/ Courtesy of: www.batmotos.com . STARTING SYSTEM DOWNTOWN 125 i INSTALLATION Coat a new O-ring (1) with engine oil and install it into the start motor groove. Install the starter motor into the crankcase. Install the two mounting bolts and engine ground cable, then tighten the bolts securely.
Page 243 Cortesia de/ Courtesy of: www.batmotos.com . STARTING SYSTEM DOWNTOWN 125 i START RELAY INSPECTION Release the rubber cap (1) and remove the nut (2), then disconnect the start motor cable. Turn the ignition switch to “ON”position. Squeeze and hold the brake lever fully then push the starter switch.
Page 244: 20. Lights/Meters/Switches
Cortesia de/ Courtesy of: www.batmotos.com 20. LIGHTS/METERS/SWITCHES DOWNTOWN125 i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LIGHTS/METERS/SWITCHES __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 20- 1 BULB REPLACEMENT --------------------------------------------------- 20- 2 BRAKE LIGHT SWITCH-------------------------------------------------- 20- 6 IGNITION SWITCH -------------------------------------------------------- 20- 6 HANDLEBAR SWITCH --------------------------------------------------- 20- 7 LUGGAGE BOX LIGHT SWITCH -------------------------------------- 20- 9 FUEL PUMP ----------------------------------------------------------------- 20-10 SIDE STAND SWITCH ---------------------------------------------------- 20-12...
Page 245: 20. Lights/Meters/Switches
Cortesia de/ Courtesy of: www.batmotos.com 20. LIGHTS/METERS/SWITCHES DOWNTOWN 125i SERVICE INFORMATION GENERAL ＊ A halogen head light bulb becomes very hot while the head light is turned on, and remains for a while after it is turned off. Be sure to let it cool down before servicing. •...
Page 246: Bulb Replacement
Cortesia de/ Courtesy of: www.batmotos.com 20. LIGHTS/METERS/SWITCHES DOWNTOWN125 i BULB REPLACEMENT POSITION LIGHT Remove the front cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Remove the bulb socket (1). Remove the bulb (2) and replace with a new one.
Page 247 Cortesia de/ Courtesy of: www.batmotos.com 20. LIGHTS/METERS/SWITCHES DOWNTOWN 125i HEADLIGHT ＊ A halogen headlight bulb becomes very hot while the headlight is ON, and remain for a while after it is turned OFF. Be sure to let it cool down before servicing.
Page 248 Cortesia de/ Courtesy of: www.batmotos.com 20. LIGHTS/METERS/SWITCHES DOWNTOWN125 i FRONT TURN SIGNAL LIGHT Remove the front cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Turn the bulb socket (1), then remove the front turn signal light . Push and turn the bulb counterclockwise to remove it, then replace with a new one..
Page 249 Cortesia de/ Courtesy of: www.batmotos.com 20. LIGHTS/METERS/SWITCHES DOWNTOWN 125i Bulb Rear turn signal light Push and turn the bulb counterclockwise to remove it, then replace with a new one. Installation is in the reverse order of removal. Taillight/Brake light Push and turn the bulb counterclockwise to remove it, then replace with a new one.
Page 250: Brake Light Switch
Cortesia de/ Courtesy of: www.batmotos.com 20. LIGHTS/METERS/SWITCHES DOWNTOWN125 i BRAKE LIGHT SWITCH Remove the upper handlebar cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect front or rear light switch connectors and check for continuity between the switch terminals (1). There should be continuity with the front or rear brake lever squeezed, and there should be no continuity with the front or rear brake...
Page 251: Handlebar Switch
Cortesia de/ Courtesy of: www.batmotos.com 20. LIGHTS/METERS/SWITCHES DOWNTOWN 125i HANDLEBAR SWITCH INSPECTION Engine Stop Switch Remove the front cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Right handlebar switch Disconnect the right handlebar switch connector and check for continuity for switch side connector terminals.
Page 252 Cortesia de/ Courtesy of: www.batmotos.com 20. LIGHTS/METERS/SWITCHES DOWNTOWN125 i Left handlebar switch Disconnect the left handlebar switch Dimmer Switch connector and check for continuity for switch side connector terminals. Continuity should exist between the color code wires as follows: Turn Signal light Switc Horn Switch Passing Switch 20-8...
Page 253: Luggage Box Light Switch
Cortesia de/ Courtesy of: www.batmotos.com 20. LIGHTS/METERS/SWITCHES DOWNTOWN 125i LUGGAGE BOX LIGHT SWITCH INSPECTION Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect the luggage box light switch connector (2) and check the luggage box light switch (1) for continuity between the switch terminals.
Page 254: Fuel Pump
Cortesia de/ Courtesy of: www.batmotos.com 20. LIGHTS/METERS/SWITCHES DOWNTOWN125 i FUEL PUMP REMOVAL Remove the seat and luggage box Remove the center cover Remove the fuel pump connector Be sure to relieve the fuel pressure before removing fuel pump or fuel hose. Remove the six nuts (1) and fuel unit connector(2) then remove the fuel hose.(3) Take out the fuel pump(4)
Page 255 Cortesia de/ Courtesy of: www.batmotos.com 20. LIGHTS/METERS/SWITCHES DOWNTOWN 125i INSPECTION Connect the fuel unit wire connectors and turn the ignition switch “ON”. ＊ Before performing the following test, operate the turn signals to determine that the battery circuit is normal. Measure the resistance between the Yellow/White and Blue/White terminals of the fuel unit connector.
Page 256: Side Stand Switch
Cortesia de/ Courtesy of: www.batmotos.com 20. LIGHTS/METERS/SWITCHES DOWNTOWN125 i SIDE STAND SWITCH INSPECTION Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Side stand switch is located on side stand Disconnect the side stand switch connector (1).
Page 257: Horn
Cortesia de/ Courtesy of: www.batmotos.com 20. LIGHTS/METERS/SWITCHES DOWNTOWN 125i HORN INSPECTION Remove the front cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2) Disconnect the horn connectors (1) from the horn. Connect a 12 V battery to the horn terminals. The horn is normal if it sounds when the 12 V battery is connected across the horn terminals.

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Sk25aa 2009

KYMCO Downtown 125i 2009 Service Manual

Preface

2. Exhaust Muffler/Frame Covers

3. Inspection/Adjustment

4. Lubrication System

6 Cylinder Head/Valves

7. Cylinder/Piston

8. Drive and Driven Pulleys

. Final Reduction 9

11. Crankcase/Crankshaft

12. Cooling System

13. Fi Diagnostic Tool Operation down Town 125I

14 Fuel System (Auto Control Fuel Injection System) 14

Handlebar/Front Wheel/Front Brake/ Front Shock Absorber/Steering Stem

Quick Links

Chapters

Troubleshooting

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Summary of Contents for KYMCO Downtown 125i 2009

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Table of Contents